Method for making a multi-lumen catheter having a separated tip section

ABSTRACT

The present disclosure is directed to a method of manufacturing a catheter wherein a dual lumen catheter body and at least one distal tip member are separately formed and the at least one distal tip member is subsequently assembled to the dual lumen catheter body. The components may be assembled using a heating process or, alternatively, using adhesives.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No. 12/835,170, filed Jul. 13, 2010, now U.S. Pat. No. 8,394,218, which claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 61/226,881, filed on Jul. 20, 2009. Each of these applications is incorporated herein by reference in its entirety.

BACKGROUND

1. Technical Field

The present disclosure relates to a method for manufacturing a multi-lumen catheter and, more particularly, to a method for manufacturing a multi-lumen catheter having a separated tip section.

2. Background of Related Art

Catheters for supplying and/or withdrawing fluids into and/or from the body are well known in the art and may be employed for medication delivery, urine removal and blood treatment, e.g., hemodialysis, to name a few. Single and multilumen catheters are well known. Typically, catheters used for hemodialysis are multilumen catheters and include a body which defines an arterial lumen and a venous lumen. During an exemplary hemodialysis procedure, a distal portion of a multilumen catheter is inserted into a patient and blood is withdrawn through the arterial lumen of the catheter. The withdrawn blood is supplied to a hemodialysis unit which purifies the blood by removing waste and toxins from the blood. Thereafter, the purified blood is returned to the patient through the venous lumen of the catheter.

One problem associated with multilumen dialysis catheters is the potential for recirculation of blood from the distal end of the venous lumen through the distal end of the arterial lumen. In an effort to minimize blood recirculation, catheters have been developed in which the arterial lumen and the venous lumen openings are laterally spaced. These catheters minimize blood recirculation by distancing the arterial lumen distal opening from the venous lumen distal opening.

Catheters can be manufactured using a variety of different techniques including, for example, thermoforming, extrusion, blow molding, rotational molding and injection molding. However, the manufacturing of dual lumen catheters with laterally spaced or separated tip sections complicates known catheter manufacturing processes.

Accordingly, a continuing need exists in the medical arts for a simpler, cost effective method for manufacturing a catheter having a separated tip section.

SUMMARY

This disclosure relates to a method of manufacturing a multilumen catheter having a separate tip section. In one embodiment, the method comprises the following steps:

i) forming a dual lumen catheter body having a proximal end and a distal end and defining a first lumen and a second lumen, the dual lumen catheter body defining a first longitudinal axis;

ii) forming a first distal tip member defining a first distal lumen portion; and

iii) assembling the first distal tip member to the distal end of the catheter portion such that the first distal lumen portion is in fluid communication with the first lumen.

In one embodiment, the assembling step includes using adhesives to secure the first distal tip member to the distal end of the dual lumen catheter body. Alternatively, the assembling step includes using heat to secure the first distal tip member to the distal end of the dual lumen catheter body.

In one embodiment, the first distal tip member defines a second longitudinal axis and the assembling step includes positioning the second longitudinal axis of the distal tip member at an angle β in relation to the first longitudinal axis of the dual lumen catheter body. Angle β is greater than 0 degrees and may be about 5 degrees or greater. Alternatively, angle β may be about 10 degrees or greater.

In another embodiment, the method further includes the following steps:

iv) forming a second distal tip member defining a second distal lumen portion; and

v) assembling the second distal tip member to the distal end of the catheter portion such that the second distal lumen portion is in fluid communication with the second lumen of the dual lumen catheter body.

As discussed above, the assembling steps may include using adhesives or heat to secure the first and second distal tip members to the distal end of the dual lumen catheter body.

In one embodiment, the first distal tip member defines a second longitudinal axis and the second distal tip member defines a third longitudinal axis, and the assembling steps include securing the first and second distal tip members to the dual lumen catheter body such that the second longitudinal axis is disposed at an angle β to the third longitudinal axis. The angle β may be about 5 degrees or greater. Alternatively, the angle β, may be about 10 degrees or greater.

In another embodiment, the second longitudinal axis is substantially parallel to the first longitudinal axis. Alternatively, the second and the third longitudinal axes are both disposed at an angle in relation to the first longitudinal axis.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the presently disclosed method for manufacturing a multilumen catheter having a separated tip configuration are disclosed herein with reference to the drawings, wherein:

FIG. 1 is a side, perspective view from the distal end of a multilumen catheter formed using the presently disclosed method of manufacturing;

FIG. 2 is a cross-sectional view taken along section lines 2-2 of FIG. 1;

FIG. 3 is a top view of the multilumen catheter shown in FIG. 1 during a first embodiment of the presently disclosed method of manufacturing with the tip sections of the multilumen catheter separated from the catheter body;

FIG. 4 is a top view of the multilumen catheter shown in FIG. 3 assembled;

FIG. 5 is a top view of an alternative embodiment of the multilumen catheter formed using the manufacturing method disclosed herein.

FIG. 6 is a top view of the multi-lumen catheter shown in FIG. 1 during a second embodiment of the presently disclosed method of manufacturing with one tip section separated from the catheter body;

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed method of manufacturing split-tip multilumen catheters will now be described in detail with reference to the drawings wherein like reference numerals designate identical or corresponding elements in each of the several views.

The exemplary embodiments of the catheter disclosed herein are discussed in terms of medical catheters for the administration of fluids (withdrawal or introduction) relative to the body of a subject and, more particularly, in terms of a hemodialysis catheter. However, it is envisioned that the present disclosure may be employed with a range of catheter applications including surgical, diagnostic and related treatments of diseases and body ailments of a subject. It is further envisioned that the principles relating to the catheter disclosed include employment with various catheter related procedures, such as, for example, hemodialysis, cardiac, abdominal, urinary, intestinal, and in chronic and acute applications. Moreover, the catheter can be used for administration of fluids such as, for example, medication, saline, bodily fluids, blood and urine.

In the discussion that follows, the term “proximal” or “trailing” will refer to the portion of a structure that is closer to a clinician, while the term “distal” or “leading” will refer to the portion that is further from the clinician. As used herein, the term “subject” refers to a human patient or other animal. The term “clinician” refers to a doctor, nurse or other care provider and may include support personnel.

FIGS. 1 and 2 illustrate a multilumen catheter 10 which is formed using the method of manufacture discussed below. Catheter 10 includes an elongated catheter body 12 which defines a first lumen 14 a and a second lumen 14 b which are separated by a septum 16. Catheter body 12 includes a proximal end (not shown) and a distal end 12 a. A separated tip section 20 is supported on the distal end 12 a of catheter body 12 and includes a first tip member 20 a and a second tip member 20 b. As used herein, the term separated tip section means that the distal end of the catheter includes first and second tip sections which are disconnected along the longitudinal axis of the catheter such that the tip members can move or be moved in relation to each other. The first tip member 20 a defines a longitudinal axes 24 and the second tip member 20 b defines a second longitudinal axis 26. Longitudinal axis 24 and 26 define an angle β greater than 0 degrees. In one embodiment, β is greater than or equal to about 5 degrees and in another embodiment β is greater than or equal to about 10 degrees. In the illustrated embodiment, longitudinal axis 24 is substantially aligned with a longitudinal axis defined by catheter body 12. However, it is envisioned that both the first and the second longitudinal axes 24 and 26 may be angularly displaced from the longitudinal axis of catheter body 12. See, for example, FIG. 5.

Each tip member 20 a and 20 b defines a tip lumen 28 and 30, respectively, which has an open distal end 28 a and 30 a, respectively. Lumen 28 of tip member 20 a is in fluid communication with lumen 14 a (FIG. 2) of catheter body 12 and lumen 30 of tip member 20 b is in fluid communication with lumen 14 b of catheter body 12. In the embodiment illustrated in FIG. 1, tip member 20 b has a longitudinal length which is greater than the longitudinal length of tip member 20 a. In one embodiment, tip member 20 b has a length which exceeds the length of tip member 20 a by between about 5 mm or more. Alternatively, the lengths of tip members 20 a and 20 b may be substantially the same.

FIG. 3 illustrates catheter 10 during the presently disclosed manufacturing process. As discussed above, catheter 10 includes a catheter body 12 having a distal end 12 a, and a separated tip section 20 having a first tip member 20 a and a second tip member 20 b. Catheter body 12 defines first and second lumens 14 a and 14 b and first and second tip members 20 a and 20 b define tip lumens 28 and 30. During the method of manufacturing catheter 10, dual lumen catheter body 12, first tip member 20 a and second tip member 20 b are formed independently. This can be accomplished using any known manufacturing technique including, as discussed above extrusion and/or injection molding. In one embodiment, each of dual lumen catheter body 12, first tip member 20 a and second tip member 20 b is formed using an extrusion process. After each of the components are extruded, the first tip member 20 a is assembled, i.e., secured or fastened, to distal end 12 a of the dual lumen catheter body 12 such that tip lumen 28 of tip member 20 a is fluidly coupled to first lumen 14 a of catheter body 12. Next, the second tip member 20 b is assembled to distal end 12 a of dual lumen catheter body 12 such that tip lumen 30 is fluidly coupled to second lumen 14 b of catheter body 12. First and second tip members 20 a and 20 b can be assembled to dual lumen catheter body 12 using heat, such as by welding, to effect covalent bonding of the thermoplastic resins of catheter body 12 and the first and second tip members 20 a and 20 b. Alternatively, first and second tip members 20 a and 20 b can be assembled to catheter body 12 using an adhesive, e.g., a slurry formulated from at least one solvent and at least one material capable of bonding to both the tip members 20 a and 20 b and the catheter body 12. Yet in another embodiment, the tip members 20 a and 20 b can be ultrasonically welded to one another, wherein ultrasonic energy is utilized to heat the contact areas of the components and form a bond. It is noted, that the tip members 20 a and 20 b, as well as the catheter body 12, can be cut or formed in any geometry to increase the surface area where these components contact one another. This is noted as it has been found that the greater the surface area the greater the bond strength will be.

As illustrated in FIG. 4, in one embodiment, first tip member 20 a is assembled to catheter body 12 such that the longitudinal axis 24 of tip member 20 a is substantially parallel to the longitudinal axis 25 of catheter body 12 and second tip member 20 a is assembled to catheter body 12 such that the longitudinal axis 26 of tip member 20 b is positioned to define an angle β, which is greater than 0 degrees, with respect to the longitudinal axis 24 of tip member 20 a. In one embodiment, angle β is about 5 degrees or greater. In another embodiment, angle β is about 10 degrees or greater.

In an alternative embodiment of the presently disclosed method shown in FIG. 5, each of tip members 120 a and 120 b of catheter 100 is assembled to distal end 112 a of catheter body 112 such that the longitudinal axes 124 and 126 of tip members 120 a and 120 b are disposed at an angle to the longitudinal axis 140 of catheter body 112 and define an angle β therebetween. As discussed above, in one embodiment, angle β is about 5 degrees or greater and in a second embodiment angle ≢ is about 10 degrees or greater. In one embodiment, tip members 120 a and 120 b are symmetrically positioned about the longitudinal axis of the catheter body 112. In this embodiment, either lumen 120 a or 120 b of catheter 100 may function as the arterial lumen or the venous lumen during a hemodialysis procedure.

Referring to FIG. 6, in an alternative embodiment of the presently disclosed manufacturing method, dual lumen catheter body 212 of catheter 200 is formed to include tip member 220 a and tip member 220 b is formed separately. As discussed above, catheter body 212 and tip member 220 b can be formed using a variety of manufacturing techniques including an extrusion process. Next, tip member 220 b is assembled to distal end 212 a of catheter body 212, using heating or adhesives, such that the longitudinal axis 226 of tip member 220 b is disposed at angle β with respect to the longitudinal axis 224 of tip member 222 a. As discussed above, angle β is greater than 0 degrees, and can be about 5 degrees or greater or, alternatively, about 10 degrees or greater. In one exemplary manufacturing process, catheter body 212 is extruded. Therefrom, a portion of the catheter is removed, using a cutting process (e.g., skiving using a blade, laser cutting, etc.), to form tip member 220 b. Tip member 220 a is formed using a separate extrusion process and then thermally bonded to catheter body 212. The thermal bonding process is achieved by inserting mandrels, which are herein defined as longitudinal members capable of fitting within both the catheter body 212 and the tip members 220 a and 220 b and can withstand the thermal energy encountered during the thermal bonding process without significant deformation. With a first mandrel inserted into distal end 212 a and extending into tip member 220 b and a second mandrel extending from catheter body 212 into tip member 220 a, thermal energy can be applied to the assembly to effectively bond the components together. The thermal energy can be applied either by using a die or by using shrink tubing. If shrink tubing is used, a first shrink tube can be inserted over the tip member 220 a and thermal energy can be applied thereto (e.g., using a heat gun) to shrink the shrink tube thereon. A second shrink tube can then be assembled over the first shrink tube, having tip member 220 a and its mandrel therein, and also over tip member 220 b and it's mandrel (i.e., effectively having both tip members 220 a and 220 b and both mandrels therein. This second shrink tube can then extend up at least a portion of the catheter body 212. Thermal energy can then be applied to the second shrink tube to join tip member 220 b to distal end 212 a. It is noted that the shrink tubing will be chosen such that it does not bond to the material employed for the catheter, such as olefins.

As illustrated in FIGS. 3 and 6, the distal end surface 250 of catheter body 212 (FIG. 6) and/or the proximal end of tip member 50 (FIG. 3) may be angled or tapered such that the distal surface of catheter body 12, 212 and the proximal surface of tip member 20 b, 220 b abut to define the desired angle β. Catheter body 12, 212 and/or tip member 20 b, 220 b can be angled during the forming process, or alternatively, during a subsequent machining process, e.g., cutting, grinding, shaving, thermal tip forming, etc.

Referring again to FIG. 5, one or more sideholes 142 can be formed on either or both of tip members 120 a and 120 b to provide additional fluid flow paths for fluid to flow into or from catheter 100. Sideholes 142 can be dispersed in any configuration or orientation about one or both tip members 120 a and 120 b. In one embodiment shown in FIG. 5, a sidehole 142 is positioned on the tip members 120 a and 120 b at a location to reduce the chance of positional occlusion. More specifically, a sidehole 142 is positioned on each of tip members 120 a and 120 b to face the adjacent tip member to minimize any likelihood of occlusion by adjacent walls of tissue, e.g., veins, heart tissue, etc., within a patient. Although sideholes 142 are only illustrated with respect to catheter 100, sideholes may also be included on catheters 10 and 200.

Although specific features of the disclosure are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the disclosure.

It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the various manufacturing processes disclosed to manufacture dual lumen catheters with expandable lumens may also be used to form a single lumen catheter with an expandable lumen where applicable. Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. 

What is claimed is:
 1. A method of manufacturing a catheter having a separated tip configuration, the method comprising: i) positioning a first mandrel in a distal end of a first lumen of a catheter body and in a first distal lumen portion defined by a first distal tip member; ii) positioning a second mandrel in a distal end of a second lumen of a catheter body and in a second distal lumen portion defined by a second distal tip member; and iii) with the second mandrel in the distal end of the second lumen and in the second distal lumen portion, thermally bonding the second distal tip member to the catheter body such that the second distal lumen portion is in fluid communication with the second lumen of the catheter body, wherein the thermal bonding further includes positioning a first shrink tube over the second distal tip member and applying thermal energy to the first shrink tube, and positioning a second shrink tube over the first shrink tube and over the first distal tip member and applying thermal energy to the second shrink tube, and wherein the catheter body defines a first longitudinal axis parallel to the first and second lumens, the second distal tip member defines a second longitudinal axis parallel to the second distal lumen portion, and thermal bonding the second distal tip member to the catheter body forms an oblique angle between the first and second longitudinal axes.
 2. The method of claim 1, further comprising removing a distal portion of the catheter body to define the first distal tip member at the distal end of the catheter body, wherein the first distal lumen portion is in fluid communication with the first lumen of the catheter body.
 3. The method of claim 1, wherein the first and second distal tip members each have an open distal end.
 4. The method of claim 1, further comprising forming sideholes in at least one of the first and second distal tip members.
 5. The method of claim 4, wherein the sideholes formed in one of the distal tip members face the other one of the distal tip members.
 6. The method of claim 1, wherein the first and second lumens of the catheter body are each D-shaped, and the first and second lumens are separated by a septum.
 7. The method of claim 6, wherein the first and second distal lumen portions are each D-shaped.
 8. The method of claim 1, wherein the thermally bonded second distal tip member is movable in relation to the first distal tip member. 